Paper coating composition containing high starch levels

ABSTRACT

Described herein is coating starch composition comprising a starch and a plasticizer, as well as a paper coating composition comprising said coating starch composition, where the paper coating composition contains at least 2% starch, a dry solids content of at least 40%, and a viscosity of less than about 1200 cPs, as well as methods of using and making such compositions, such as, for example, in paper manufacturing processes.

This Application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/809,177 filed Feb. 22, 2019 and U.S. Provisional PatentApplication Ser. No. 62/855,461 filed May 31, 2019, both of which areincorporated herein in their entirety.

Described herein is coating starch composition comprising a starch and aplasticizer, as well as a paper coating composition comprising saidcoating starch composition, where the paper coating composition containsat least 2% starch, a dry solids content of at least 40%, and aviscosity of less than about 1200 cPs, as well as methods of using andmaking such compositions, such as, for example, in paper manufacturingprocesses. The paper and board produced with one or more paper coatingcomposition described herein meets desired strength requirements withouthaving to add more starch before applying said one or more paper coatingcomposition via, e.g., the coaters (i.e., eliminates, e.g., the additionof starch via a wet stack calendering or size press step).

The following description is provided to assist the understanding of thereader. None of the information provided or references cited is admittedto be prior art to the compositions and methods disclosed herein.

Coated paper and paperboard require a certain level of surface strengthto withstand the stresses of the ink tack in a printing process. Tofurther increase the surface strength of paper or paperboard, thesurface of the paper or paperboard is often treated with a first coatingof starch applied at, e.g., a wet stack calender or size press prior tobeing coated with a second coating of starch via a paper coatingcomposition. Manufacturers employing a wet stack calender in thepaper-making/paperboard-making process frequently sacrifice machinespeed, board density (e.g., too heavy for a given caliper), quality, anduptime associated with the use of, e.g., a wet stack calender or sizepress. Moreover, adding starch via a first coating at, e.g., a wet stackcalender or size press before coating the paper or paperboard with asecond coating of starch via the paper coating composition at, e.g., acoater increases the costs associated with manufacturing the paper orpaperboard. As a result, there is a need to eliminate the first coatingof starch applied at, e.g., a wet stack calender or size press, beforecoating the paper or paperboard with a second coating of starch via apaper coating composition at, e.g., a coater without compromising thesurface strength and quality of the resulting paper or paperboard.

Disclosed herein is one or more paper coating composition containing thelevel of starch required to produce paper or board with the requiredsurface strength and quality while still having the desired viscosityand solids content that manufacturers demand, and which also enables thefirst coating of starch that was applied at, e.g., a wet calender orsize press to be eliminated. More specifically, described herein is oneor more paper coating composition comprising a coating starchcomposition comprising a starch and a plasticizer, wherein said papercoating composition contains at least about 2%, from about 2% to about30%, from about 2% to about 25%, from about 2% to about 22%, or fromabout 2% to about 10% starch. Another embodiment describes one or morepaper coating composition that has (i) a viscosity of less than 1200cPs, about 100 to about 1200 cPs, about 200 to about 1200 cps, or about300 to about 600 cPs and a solids content of at least 40%, 45%, 50%,55%, 60%, 65% or 70% dry solids (ds) basis, or (ii) a viscosity of about300 to about 600 cPs and a solids content of at least 60% dry solids(ds) basis; and, optionally, wherein the viscosity is measured on aBrookfield Viscometer at 20 rpm at 18.3° C. Still a further embodimentdescribes a coating starch composition comprising a starch and aplasticizer, where the coating starch composition has a starch andplasticizer solids level of at least 40% ds basis. Yet still a furtherembodiment describes a coating starch composition containing 1 partstarch for each 1, 1.5, 2, 2.5, 3, 3.5, or 4 parts plasticizer. An evenstill further embodiment describes a paper coating compositioncontaining from 2 to 20 parts of the starch and from 5 to 35 parts ofthe plasticizer, from 2 to 10 parts of the starch and from 5 to 25 partsof the plasticizer, or 10 parts of the starch and 25 parts of theplasticizer. A still yet further embodiment describes a paper substratecomprising, on at least one surface, one or more paper coatingcomposition described herein.

Another embodiment disclosed herein provides a method of manufacturing adry-finished, coated paper or paperboard product comprising applying oneor more paper coating composition described herein to at least one sideof a paper or paperboard, and obtaining a dry finished, coated paper orpaperboard. Yet another embodiment disclosed herein provides a method ofmanufacturing a dry-finished, coated paper or paperboard productcomprising applying one or more paper coating composition describedherein to at least one side of a paper or paperboard, and obtaining adry finished, coated paper or paperboard, with the proviso that themethod does not comprise a wet stack calendering step prior to applyingone or more paper coating composition described herein. Some embodimentsdescribe one or more methods where no starch is applied to the paper orpaperboard prior to or after the application of one or more papercoating composition described herein. In some embodiments, one or moremethod described herein eliminates the use of a wet stack calenderingstep prior to the application of one or more paper coating compositiondescribed herein. In some embodiments, one or more paper coatingcomposition described herein is applied to the paper or paperboard at acoater.

Still other embodiments describe a dry-finished, coated paper orpaperboard product produced from one or more method described herein. Insome embodiments, the dry-finished paper or paperboard is characterizedby a surface strength equivalent to that of a wet-finished paper orpaperboard product as measured by an IGT pick and blister test.

It is to be appreciated that certain aspects, modes, embodiments,variations, and features of the present technology are described belowin various levels of detail in order to provide a substantialunderstanding of the present technology. The definitions of certainterms as used in this specification are provided below. Unless definedotherwise, all technical and scientific terms used herein generally havethe same meaning as commonly understood by one of ordinary skill in theart to which this present technology belongs.

I. Definitions

The following terms are used herein, the definitions of which areprovided for guidance.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the elements (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Recitation of ranges of values herein are merely intended toserve as a shorthand method of referring individually to each separatevalue falling within the range, unless otherwise indicated herein, andeach separate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the embodiments and does not pose alimitation on the scope of the claims unless otherwise stated. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential.

As used herein, “about” will be understood by persons of ordinary skillin the art and will vary to some extent depending upon the context inwhich it is used. If there are uses of the term which are not clear topersons of ordinary skill in the art, given the context in which it isused, “about” will mean up to plus or minus 10% of the particular term.

As used herein, the term “DE” or “Dextrose Equivalent” refers to thedegree of starch hydrolysis, specifically reducing the value of a starchhydrolysate compared to the reducing value of an equal weight ofdextrose, expressed as percent, dry basis, as measured by the Lane anyEynon method described in Standard Analytical Method E-26, Corn RefinersAssociation, 6^(th) Edition 1977, pp. 1-3.

As used herein, the term “DP” refers to the number of saccharide units.For example “DP1” saccharide is intended herein to refer to amonosaccharide, such as dextrose.

As used herein, “dry finish” or “dry finished” is paper or paperboard towhich no starch is added at, e.g., a wet stack calender prior to, e.g.,a coater.

As used herein, “low sugar syrup” means a syrup that has low mono- anddi-saccharide content, such as, for example, a DP1+DP2 content less thanabout 65%, less than about 25%, or less than about 20%, less than about19%, less than about 18%, less than about 17% less than about 16%, lessthan about 15%, less than about 14%, less than about 13%, less thanabout 12%, less than about 11%, or less than about 10%. Exemplarycommercial low sugar syrups include but are not limited to VERSASWEET™1524 low sugar glucose syrup VERSASWEET® 1526 low sugar glucose syrup,VERSASWEET® 1526 NGM low sugar glucose syrup, VERSASWEET® 1531 low sugarglucose syrup, STABLESWEET® glucose syrup, BIOLIGIO® ML6810 glucosesyrup (Ingredion Inc.), MULTIVANTAGE® syrup (Tate & Lyle), VERSYRA™reduced sugar corn syrup, and CLEARDEX® corn syrup (Cargill).

The terms “paper,” “paperboard,” “recycled board,” and “board,” are usedinterchangeably herein. Paper and paperboard are sheet materials made upfrom an interlaced network of cellulose fibers. The distinction betweenpaper and paperboard is not great; however, in general, paperboard isthicker than paper and has a higher weight per unit area. Paper over 200g/m² is defined by the International Organization for Standardization(ISO) as paperboard or board. However, some products are known aspaperboard even though they are manufactured in grammages less than 200g/m². Broad classes within paperboard include containerboard, boxboard,and all other paperboard. “Recycled paperboard” is paperboardmanufactured using recovered paper, such as newspapers, corrugatedcontainers, and mixed papers. Recycled paperboard containers include,but are not limited to, linerboard and corrugating medium, foldingboxboard used for packaging cereal and other food products, soappowders, and other dry products, and set-up boxboard. Recycledpaperboard is also used for many non-packaging products, including butnot limited to, gypsum wallboard facing, tubes, cans, drums, matches,tags, tickets, game boards, and puzzles.

As used herein, a “plasticizer” means any material that competes forhydrogen bonding with starch molecules and thus disrupts hydrogenbonding between the starch molecules. This increases the flexibility ofa film made with starch and other components. Examples of materials thatplasticize starch include glycerin/glycerol, urea, formamide, citricacid (and other carboxylic acids), ethylene glycol, sugars (e.g.sucrose), maltodextrins, dextrin, starch derived syrups (such as cornsyrup), and sugar alcohols (e.g., sorbitol and maltitol). Many of theplasticizers, especially the sugars, maltodextrins, and starch derivedsyrups listed above are or can be derived from a carbohydrate sourcesuch as starch. Starch can be obtained from any farinaceous materialincluding, but not limited to, for example, corn, dent corn, waxy corn,wheat, potato, tapioca, peas, sorghum, manioc, sago, and rice.

As used herein, “wet finish” or “wet finished” is paper or paperboardmade by adding starch at, for example, a wet stack calender prior toalso being added at, for example, a coater.

As used herein, “IGT Coating Blister” refers to a physical test thatmeasures the surface strength of coating layers applied to paper orpaper board. The test predicts the point where forces applied to theboard through ink tack build in printing causes the internal layers ofthe board to blister and is used to predict or measure the potentialprintability of the board coating layers.

As used herein, “IGT Coating Pick” refers to a physical test thatmeasures the surface strength of coating layers applied to paper orpaper board. This test is used to measure the ability of a coating toresist picking as a function of increasing ink tack build withincreasing velocity.

As used herein, “basis weight” refers to the weight of a paper orpaperboard for a defined area.

As used herein, “caliper” means the thickness of the paper orpaperboard.

As used herein, “base coat weight” refers to the weight of the coatingwhen applied to a defined area as a base coat.

As used herein, “coated brightness” refers to an optical measurement ofthe coated paper or paperboard surface for the brightness or whitenessof the surface. It is a measure of the visual appearance of the paper orpaperboard.

As used herein, “Appearance DMM” means the appearance according toDuPont mottle measurement, which is a quantification of the amount ofsurface mottle measured when a paper or paper board is scanned under adiffuse lighting scanner. It is a measure of the visual appearance ofthe paper or paperboard.

As used herein, “Appearance DAV2” means the appearance according toDuPont Appearance Value (version 2), which is an optical test thatmeasures the visual appearance of a paper or paper board surface underseveral lighting or illumination sources. It is a measure of the visualappearance of the paper or paperboard.

As used herein, “Sheffield smoothness” is a measurement of thesmoothness of a surface of a paper or paper board.

II. General

Coated paper and paperboard require a certain level of surface strengthto withstand the stresses of the ink tack in a printing process. Thesurface of the paper or board is typically treated with a first coatingof starch applied at, e.g., a wet stack calender or size press, followedby a second coating of starch applied at, e.g., a coater. In a coatedpaper or board manufacturing process that involve the application of afirst coating of starch at, e.g., a wet stack calender, manufacturerssacrifice machine speed, board density, quality, and uptime.

In conventional coated paperboard manufacturing processes, rawstock fromthe paper machine is surface sized and then machine calendered prior tocoating. During sizing, substances such as gelatin, rosin, starch, orother synthetic substances, are added to paper board to improveresistance of the paperboard to liquid or vapor. Calendering is aprocess that smooths and controls the caliper or thickness of thepaperboard. In a typical wet stack calendering process, water from oneor more water boxes is applied to the paperboard to enhance thecalendering results and add binders like starch, but not withoutdetrimental side effects. For example, a wet calendaring step causes thecaliper of the paperboard to be reduced while also increasing itsdensity. Accordingly, in order to achieve a certain caliper, additionalrawstock will be required, resulting in additional raw materials costs.In addition, wet finishing creates operating problems including surfacemottling of the paperboard, web breaks, and corrosion on the machine.

A particular challenge associated with removing the first coating ofstarch applied at, e.g., a wet stack calender or size press, before thepaper or board is coated with the second coating of starch via the papercoating composition subsequently applied at, e.g., a coater, ismaintaining the surface strength and quality of the paper or paperboardbeing manufactured. A further challenge with eliminating the firstcoating of starch applied at, e.g., a wet stack calender or size press,is providing a paper coating composition that contains enough starch toprovide the desired surface strength and quality while also having thedesired viscosity and solids content manufacturers demand. Starch isoften applied as a strengthening agent during the paperboardmanufacturing process. To further increase the surface strength of thepaperboard, it may be desirable to increase the amount of starch in thepaper coating composition; however, increasing the level of starch inthe paper coating composition will result in a highly-viscous, gel-likecomposition that is difficult to handle, pump, and/or mix with otheringredients, and therefore may negatively impact the production speed ofthe manufacturing equipment.

Accordingly, there is a need to develop a paper coating composition thatwill maintain an appropriate coating viscosity for application duringpaperboard manufacturing, impart the desired strength characteristics tothe manufactured paperboard, have the desired solids content to limitthe amount of water that has to be driven off, and that allowsmanufacturers to eliminate the addition of starch before or after thepaper or paperboard is coated with the starch containing paper coatingcomposition without sacrificing the strength and quality of thepaperboard. One or more paper coating compositions described hereinexhibit one or more of the aforementioned benefits, includingeliminating the wet stack calendaring step and/or the addition of starchvia the wet stack calendaring or size press steps, thereby decreasingmanufacturing costs while improving manufacturing speed.

It has been shown that the addition of a plasticizer, such as, forexample, corn syrup to a paper coating composition in equal amounts ofsolids lowers the viscosity of the paper coating composition. At higherstarch levels, the addition of a plasticizer, such as, for example, cornsyrup maintains the viscosity of the paper coating composition. Due toits relatively low molecular weight, one of skill in the art would notanticipate that a plasticizer, such as, for example, corn syrup would becapable of improving the strengthening properties of a paper coatingcomposition. However, as demonstrated by the results described below,one or more paper coating composition described herein surprisingly andunexpectedly shows that a plasticizer, such as, for example, corn syrupin combination with starch provides paper and board with excellentstrength over paper coating compositions that do not contain aplasticizer, such as, for example, corn syrup. One or more paper coatingcomposition disclosed herein enables a dry finished board (no starchadded at the wet stack calender) having strength characteristicscomparable to those of a wet finished board (starch added at the wetstack calender) to be manufactured after only a single application ofone or more starch containing paper coating compositions describedherein to the dry finished, coated paper or board (i.e., a singleapplication of one or more paper coating compositions described herein,which enables the addition of starch at the wet stack to be eliminated).As a result, one or more paper coating composition described hereinenables less total starch to be unexpectedly and surprisingly used in apaperboard manufacturing process (e.g., ˜33 lbs/ton (˜16.5 kg/metricton) present method vs. ˜60 lbs/ton (˜30 kg/metric ton) conventionalmethod).

Disclosed herein is a starch coating composition and a paper coatingcomposition that enables an improved, simplified paper and paper boardmanufacturing process. One or more method described herein for using oneor more paper coating compositions described herein provides apaperboard manufacturing process that eliminates the wet stackcalendaring step, reduce manufacturing time, improves efficiency,improves water retention, improves runnability, improves yield (e.g.,caliper vs. basis weight), reduces costs associated with the use ofstarch at the wet calendering or size press steps, and provide greaterflexibility, without compromising the strength and quality of thepaperboard. Various embodiments can provide a dry finished, coated paperor board with an IGT surface strength profile that is comparable to thatof a wet finished, coated paper or board, thereby eliminating the needfor an additional starch application at the wet stack calendaring orsize press steps. Additionally, or alternatively, in some embodiments,one or more composition described herein may eliminate vessel segmentpicking in mills that do not have size presses and use oak or other hardwoods as part of their fiber basket.

III. Paper Coating Compositions and Coating Starch Compositions

Described herein is a coating starch composition comprising a starch andplasticizer, a starch and a non-carbohydrate derived plasticizer, astarch and a carbohydrate derived plasticizer, or a starch and a starchderived syrup. In some embodiments, one or more coating starchcomposition described herein has a starch and plasticizer, a starch anda non-carbohydrate derived plasticizer, a starch and a carbohydratederived plasticizer, or a starch and a starch derived syrup solids levelof at least 40% dry solids (ds) basis. In other embodiments, one or morecoating starch composition described herein contains 1 part of a starchfor each 1, 1.5, 2, 2.5, 3, 3.5, or 4 parts of a plasticizer. In yetother embodiments, one or more coating starch composition describedherein contains 1 part of a starch for each 2, 2.5, 3, 3.5, or 4 partsof a plasticizer. In yet other embodiments, one or more coating starchcomposition described herein contains 1 part of a starch for each 2.5parts of a plasticizer. In still other embodiments, one or more coatingstarch composition described herein contains 1 part of a starch for each2.5 parts of a starch derived syrup. In some embodiments, one or morecoating starch composition described herein contains 1 part PEN-COTE®L800 (Ingredion) starch for each 2.5 parts of maltose syrup with a DE of53, such as, for example, GLOBE® 55 HM Corn Syrup (Ingredion).

Also, described herein is a paper coating composition comprising one ormore coating starch compositions described herein. In some embodiments,one or more paper coating composition described herein contains at leastabout 2%, from about 2% to about 30%, from about 2% to about 25%, fromabout 2% to about 22%, or from about 2% to about 10% starch. In otherembodiments, one or more paper coating composition described herein hasa viscosity of less than 1200 cPs. In some embodiments, one or morepaper coating composition described herein has a viscosity of less than1100 cPs, less than 1000 cPs, less than 900 cPs, less than 800 cPs, lessthan 700 cPs, less than 600 cPs, or less than 500 cPs, including any andall ranges and subranges therein. In other embodiments, one or morepaper coating composition described herein has a viscosity of less than1200 cPs, about 100 to about 1200 cPs, about 200 to about 1200 cps, orabout 300 to about 600 cPs including any and all ranges and subrangestherein. In further embodiments, one or more paper coating compositiondescribed herein has a viscosity of about 300 to about 600 cPs. In stillother embodiments, one or more paper coating composition describedherein has a viscosity of about 600 to about 700 cPs. In even yet otherembodiments, one or more paper coating composition described herein hasa viscosity of about 500 to about 600 cPs.

In still other embodiments, one or more paper coating compositiondescribed herein has a solids content of at least 40% dry solids (ds)basis. In some embodiments, one or more paper coating compositiondescribed herein has a solids content of at least 40% ds basis, at least45% ds basis, at least 50% ds basis, at least 55% ds basis, at least 60%ds basis, at least 65% ds basis, or at least 70% ds basis. In someembodiments, one or more paper coating composition described herein hasa solids content of at least 45% ds basis, at least 50% ds basis, or atleast 60% ds basis. In yet other embodiments, one or more paper coatingcomposition described herein has a solids content of about 40% to about70% ds basis, about 50% to about 65% ds basis, or about 55% to about 65%ds basis. In some embodiments, one or more paper coating compositiondescribed herein has a solids content of about 60% to about 65% dsbasis, about 61% ds basis, about 62% ds basis, about 63% ds basis, about64% ds basis, or about 65% ds basis.

In yet still other embodiments, one or more paper coating compositiondescribed herein has (i) a viscosity of less than 1200 cPs, about 100 toabout 1200 cPs, about 200 to about 1200 cps, or about 300 to about 600cPs and a solids content of at least 40%, 45%, 50%, 55%, 60%, 65% or 70%ds basis, or (ii) a viscosity of about 300 to about 600 cPs and a solidscontent of at least about 60% ds basis.

In yet still an even further embodiment, one or more paper coatingcomposition described herein contains at least about 2%, from about 2%to about 30%, from about 2% to about 25%, from about 2% to about 22%, orfrom about 2% to about 10% starch and has (i) a viscosity of less than1200 cPs, about 100 to about 1200 cPs, about 200 to about 1200 cps, orabout 300 to about 600 cPs and a solids content of at least 40%, 45%,50%, 55%, 60%, 65% or 70% ds basis, or (ii) a viscosity of about 300 toabout 600 cPs and a solids content of at least about 60% ds basis.

In still other embodiments, one or more paper coating compositiondescribed herein further comprises a pigment and/or a latex.

In some embodiments, one or more paper coating composition describedherein and/or one or more coating starch composition described hereinenable methods for the production of a dry finished board havingimproved surface strength and/or a surface strength that is comparableto a wet finished board.

In other embodiments, one or more coating starch compositions describedherein provide a means of adding more starch to one or more papercoating compositions described herein while at the same time avoidingnegative attributes such as increasing the viscosity of the papercoating composition or decreasing the solids content. In someembodiments, one or more coating starch composition described hereinallows the amount of starch added to a paper coating composition to beincreased by at least 2-fold while maintaining a viscosity suitable forcoating paper or paperboard as compared to a standard coating starchcomposition. In still other embodiments, one or more coating starchcomposition described herein enables methods for producing a dryfinished board having improved surface strength and/or a surfacestrength that is comparable to a wet finished board while eliminatingthe need for a wet stack calendering step in the paper manufacturingprocess and/or eliminating the need to apply starch to the board at thewet stack calender and/or eliminating the need to apply starch to theboard at any point prior to or after applying one or more paper coatingcomposition containing one or more coating starch composition describedherein. In yet other embodiments, one or more coating starchcompositions described herein enables methods for producing a dryfinished board having improved surface strength and/or a surfacestrength that is comparable to a wet finished board while reducing theoverall amount of starch used in methods for manufacturing paper orboard without compromising the surface strength of the paper or board.In even still other embodiments, one or more coating starch compositiondescribed herein enables methods for producing a dry finished boardhaving improved surface strength and/or a surface strength that iscomparable to a wet finished board while reducing the amount of starchemployed in the paper-manufacturing method.

In some embodiments, one or more paper coating composition describedherein comprises from 2 to 20 parts of a starch and from 5 to 35 partsof a plasticizer. In other embodiments, one or more paper coatingcomposition described herein comprises from 2 to 10 parts of a starchand from 5 to 25 parts of a plasticizer. In yet still other embodiments,one or more paper coating composition described herein comprises 10parts of a starch and 25 parts of a plasticizer. In even yet furtherembodiments, one or more paper coating composition described hereincomprises from 2 to 20 parts of a starch and from 5 to 35 parts of astarch derived syrup. In yet even further embodiments, one or more papercoating composition described herein comprises from 2 to 10 parts of astarch and from 5 to 25 parts of a starch derived syrup. In even yetstill other embodiments, one or more paper coating composition describedherein comprises 10 parts of a starch and 25 parts of a starch derivedsyrup.

In further embodiments, one or more paper coating composition describedherein enables methods for producing a dry finished board havingimproved surface strength and/or a surface strength that is comparableto a wet finished board while eliminating the need for a wet stackcalendering step in the paper manufacturing process and/or eliminatingthe need to apply starch to the board at the wet stack and/oreliminating the need to apply starch to the board at any point prior toor after the application of one or more paper coating compositiondescribed herein. In even still further embodiments, one or more papercoating composition described herein enables methods for producing a dryfinished board having improved surface strength and/or a surfacestrength that is comparable to a wet finished board while reducing theoverall amount of starch used in methods for manufacturing paper orboard without compromising the surface strength of the paper or board.In yet other embodiments, one or more paper coating compositiondescribed herein enables methods for producing a dry finished boardhaving improved surface strength and/or a surface strength that iscomparable to a wet finished board while reducing the amount of starchused in the paper-manufacturing method.

In some embodiments, one or more coating starch composition describedherein or one or more paper coating composition described herein allowsthe amount of starch employed in the overall paper-manufacturing methodto be reduced from approximately 60 lbs starch per ton (˜30 kg/metricton) of paperboard to approximately 33 lbs of starch per ton (˜16.5kg/metric ton) of paperboard. In some embodiments, one or more papercoating composition described herein or one or more coating starchcomposition described herein enables the amount of starch employed inthe paper-manufacturing method to be reduced by at least 5%, at least10%, at least 15%, at least 20%, at least 25%, at least 30%, at least35%, at least 40%, at least 45%, at least 50%, at least 55%, or at least60%, including any and all ranges and subranges therein. In someembodiments, one or more paper coating composition described herein orone or more coating starch composition described herein enables theamount of starch used in the paper-manufacturing method to be reduced byfrom about 10% to about 60%, from about 15% to about 55%, from about 20%to about 50%, from about 25% to about 50%, from about 30% to about 50%,or from about 40% to about 50%. In some embodiments, one or more papercoating composition described herein or one or more coating starchcomposition described herein enables the amount of starch used in thepaper-manufacturing method to be reduced by from about 40% to about 45%.In some embodiments, one or more paper coating composition describedherein or one or more coating starch composition described hereinenables the amount of starch used in the paper-manufacturing method tobe reduced by from about 45% to about 50%.

A. Plasticizer

In one embodiment, the plasticizer is a non-carbohydrate derivedplasticizer, a carbohydrate derived plasticizer, or a mixture thereof.In another embodiment, the non-carbohydrate derived plasticizer isselected from urea, glycerin/glycerol, ethylene glycol, formamide,citric acid or other carboxylic acids, and a mixture of any two or moreof the foregoing. In another embodiment, the carbohydrate derivedplasticizer is a sugar. In still another embodiment, the sugar isselected from a sucrose, a starch derived syrup, a maltodextrin, adextrin, a sugar alcohol, or a mixture of any two or more of theforegoing. In yet still another embodiment, the carbohydrate derivedplasticizer is a starch derived syrup. In still another embodiment, thesugar alcohol is a sorbitol.

The starch derived syrup may be any type of starch derived syrupsuitable for use in paper coating formulations. In some embodiments, thestarch derived syrup is selected from a corn syrup, a low sugar syrup,dextrose, or a mixture of any two or more of the foregoing. In someembodiments, the starch derived syrup is a corn syrup. In furtherembodiments, the starch derived syrup is a low sugar syrup. In furtherembodiments, the corn syrup is a maltose corn syrup or high fructosecorn syrup. In some embodiments, the corn syrup is a maltose corn syrup.In some embodiments, the corn syrup is a high fructose corn syrup. Insome embodiments, the corn syrup is a maltose corn syrup with a DE of53, such as GLOBE® 55 HM Corn Syrup (Ingredion). In some embodiments,the corn syrup is a high fructose corn syrup.

In some embodiments, the starch derived syrup has a DE of about 20 toabout 100. In some embodiments, the starch derived syrup has a DE ofabout 30 to about 100, about 35 to about 100, about 40 to about 100,about 45 to about 100, about 50 to about 100, about 55 to about 100,about 60 to about 100, about 65 to about 100, about 70 to about 100,about 75 to about 100, about 80 to about 100, about 85 to about 100,about 90 to about 100, or about 95 to about 100, including any and allranges and subranges therein. In other embodiments, the starch derivedsyrup has a DE of about 20 to about 90, about 30 to about 90, about 35to about 90, about 40 to about 90, about 45 to about 90, about 50 toabout 90, about 55 to about 90, about 60 to about 90, about 65 to about90, about 70 to about 90, about 75 to about 90, about 80 to about 90, orabout 85 to about 90, including any and all ranges and subrangestherein. In other embodiments, the starch derived syrup has a DE ofabout 20 to about 90, about 20 to about 100, about 40 to about 75, about40 to about 70, about 40 to about 44, about 49 to about 55, about 53 or53. In some embodiments, the starch derived syrup includes any starchderived syrup having a DE of about 40 to about 75. In some embodiments,the starch derived syrup has a DE of about 40 to about 70, about 40 toabout 44, about 50 to about 55, about 53 or 53.

B. Starch

In one embodiment, the starch is obtained or derived from one or acombination of farinaceous materials. Any farinaceous material can beused as the source of the starch including corn, dent corn, waxy corn,wheat, potato, tapioca, pea, sorghum, manioc, sago, and rice, amongothers. Accordingly, the starch can be comprised of one or moreunmodified starch, blends of different types of unmodified starches, oneor more modified starch, blends of different types of modified starches,and/or blends of modified and unmodified starches. In some embodiments,the starch is selected from corn starch, dent corn starch, waxy cornstarch, wheat starch, potato starch, tapioca starch, pea starch, sorghumstarch, manioc starch, sago starch, rice starch, and a mixture of anytwo or more of the foregoing. In other embodiments, that starch isselected from one or more of unmodified or modified corn starch,unmodified or modified dent corn starch, unmodified or modified waxycorn starch, unmodified or modified wheat starch, unmodified or modifiedpotato starch, unmodified or modified tapioca starch, unmodified ormodified pea starch, unmodified or modified sorghum starch, unmodifiedor modified manioc starch, unmodified or modified sago starch,unmodified or modified rice starch, and blends of two or more of any ofthe foregoing.

In some embodiments, the starch may be modified in any manner known inthe art.

In some embodiments, the starch is a thinned starch. Exemplarycommercial thinned starches, include but are not limited to PENFORD® GUM230, PENFORD® GUM 240, PENFORD® GUM 250, PENFORD® GUM 260, PENFORD® GUM270, PENFORD® GUM 280, PEN-COTE®, FILMKOTE® 340, FILMKOTE® 355,FILMKOTE® 370, FILMKOTE® 54, FILMKOTE® 550, FILMKOTE® 70, PENFILM™ 2230,PENFILM™ 2240, StacKote® 4, StacKote® 6, or StacKote® 8 (IngredionInc.). In some embodiments, the thinned starch is a stable liquidcoating starch. Exemplary stable liquid coating starches include but arenot limited to PEN-COTE® L800, PEN-COTE® L1000, RediFILM™ 5400,RediFILM™ 5800, or RediBOND™ HM12 (Ingredion Inc.). In some embodiments,the starch is a modified starch. In other embodiments, the modifiedstarch is selected from a nonionic starch, an anionic starch, anamphoteric starch, an etherified starch, an acetylated starch, asulfonated starch, and a mixture of any two or more of the foregoing.

C. Additives/Other Components

In some embodiments, one or more paper coating composition describedherein further comprises a pigment and/or a latex. Exemplary pigmentsinclude but are not limited to clay, calcium carbonate, TiO₂, or anycombination thereof. Exemplary latexes include but are not limited tovinyl acrylic, polyvinyl acetate (PVAC), styrene butadiene, styreneacrylate, or any combination thereof. In some embodiments, one or morepaper coating composition described herein further comprises about 100parts pigment and about 10 to about 25 parts latex.

D. Coating Applications and Surfaces

One or more paper coating composition described herein and/or one ormore coating starch composition described herein may be adapted for usein a number of applications, including in compositions used in thepaper-making processes. In particular, one or more paper coatingcomposition described herein and/or one or more coating starchcomposition described herein are adaptable for use in coatings used tomake dry finished paper and paperboard. In addition to paper andpaperboard, one or more paper coating composition described hereinand/or one or more coating starch composition described herein can beapplied to parchment, cellophane, metals, textiles, or like surfacesthat are wettable by water. One or more paper coating compositiondescribed herein and/or one or more coating starch composition describedherein are useful, for example, in applications where contact with anaqueous solution is possible, such as, e.g., in offset printing.

One or more paper coating composition described herein, such as, e.g.,coatings on paper and paperboard, are desirable for subsequentoperations, such as, e.g., printing, and the like. As the Examples setforth herein demonstrate, dry finished paperboard coated with one ormore paper coating composition described herein resists picking andblistering during offset printing to an extent that is comparable tothat of a wet finished paperboard coated with a standard first starchcoating applied, for example, via a wet stack calendar or size press,followed by a second standard coating applied, for example via a coater(hereinafter “conventional paper coating process”).

Paper and paperboard coated with one or more paper coating compositiondescribed herein may have any surface strength. In some embodiments, adry finished paperboard coated with one or more paper coatingcomposition described herein has a surface strength that is comparableor increased relative to a wet finished paperboard coated with standardpaper coating compositions via a conventional paper coating process.Examples of physical tests of a substrate's (e.g., paper, board, etc.)surface strength that correlate well with a substrate's printperformance are the IGT pick and blister tests and wax pick tests. Inaddition, both tests correlate well with strong surface strength ofpaper substrates. While either of these tests may be utilized, the IGTpick test is preferred. In some embodiments, a dry-finished coated paperor paperboard product coated with one or more paper coating compositiondescribed herein is characterized by an IGT average increase of at least50%, 55%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, or 70% ascompared to a dry-finished paper or paperboard product coated withstandard paper coating compositions via a conventional paper coatingprocess

The IGT tests predict the ability of coated or uncoated paper orpaperboard to resist picking or blistering during offset printing. Thetest device operates by applying a known film thickness of polybutyneoil of a given viscosity to an aluminum printing disk. The oil isapplied to the disk with a standard IGT inking unity. The oil istransferred to the sample surface while under acceleration. The oilcreates a pulling action on the paper surface, similar to offset ink,resulting in picking, blistering, or both. The point at which thepicking and blistering starts is the end point of the test. The reportedunits for both pick and blister are Kilopoise-Centimeters per second(KPCMS). At a known oil viscosity, this value relates to the velocity orpress speed that can be achieved before the sheet is damaged.

One or more dry finished paper or board described herein may have atleast one surface having a surface strength as measured by the IGT pickand blister test of at least 35 KPCMS, at least 40 KPCMS, at least 45KPCMS, at least 50 KPCMS, at least 55 KPCMS, at least 60 KPCMS, at least65 KPCMS, at least 66 KPCMS, at least 67 KPCMS, at least 68 KPCMS, atleast 69 KPCMS, at least 70 KPCMS, at least 71 KPCMS, at least 72 KPCMS,at least 73 KPCMS, at least 74 KPCMS, at least 75 KPCMS, at least 76KPCMS, at least 78 KPCMS, at least 79 KPCMS, or at least 80 KPCMS,including any and all values therein.

Paper coating compositions described herein can be applied to one orboth sides of the paper or paperboard by any means known in the art.Coating methods include, but are not limited to, roll applicator andmetering with roll, rod, blade, bar, or air knife; pond application andmetering with roll, rod, blade, or bar, or air knife; premetered filmsor patterns; foam application; curtain coaters; and combinations of anyof the foregoing.

Subject matter contemplated by the present disclosure is set out in thefollowing numbered embodiments:

1. A coating starch composition comprising a starch and a plasticizer,wherein said composition has a starch and plasticizer solids level of atleast 40% dry solids (ds) basis.

2. The coating starch composition of embodiment 1, wherein saidcomposition contains 1 part of a starch for each 1, 1.5, 2, 2.5, 3, 3.5,or 4 parts of a plasticizer.

3. The coating composition of embodiment 1 or 2, where said plasticizeris a non-carbohydrate derived plasticizer, a carbohydrate derivedplasticizer, or a mixture thereof.

4. The coating composition of embodiment 3, where said non-carbohydratederived plasticizer is selected from urea, glycerin/glycerol, formamide,citric acid or other carboxylic acids, ethylene glycol, and a mixture ofany two or more of the foregoing.

5. The coating composition of embodiment 3, where said carbohydratederived plasticizer is (i) a sugar; (ii) a sucrose, a starch derivedsyrup, a maltodextrin, a dextrin, a sugar alcohol, or a mixture of anytwo or more of the foregoing; (iii) a starch derived syrup selected froma corn syrup, a low sugar syrup, dextrose, or a mixture of any two ormore of the foregoing; (iv) a maltose corn syrup or a high fructose cornsyrup; or (v) a sorbitol.

6. The coating composition of embodiment 5, wherein said starch derivedsyrup has a dextrose equivalency (DE) of about 20 to about 90, about 20to about 100, about 40 to about 75, about 40 to about 70, about 40 toabout 44, about 49 to about 55, about 53 or 53.

7. The coating starch composition of any preceding embodiment, whereinsaid plasticizer is a corn syrup selected from maltose corn syrup, highfructose corn syrup, and a mixture thereof.

8. The coating starch composition of any preceding embodiment, whereinthe starch is a modified starch selected from a nonionic starch, ananionic starch, an amphoteric starch, an etherified starch, anacetylated starch, a sulfonated starch, and a mixture of any two or moreof the foregoing.

9. The coating starch composition of any preceding embodiment, whereinthe starch is selected from corn starch, dent corn starch, waxy cornstarch, wheat starch, potato starch, tapioca starch, pea starch, sorghumstarch, manioc starch, sago starch, rice starch, and a mixture of anytwo or more of the foregoing.

10. A paper coating composition comprising the coating starchcomposition of any preceding embodiment, wherein said compositioncontains at least about 2%, from about 2% to about 30%, from about 2% toabout 25%, from about 2% to about 22%, or from about 2% to about 10%starch.

11. The paper coating composition of embodiment 10, wherein thecomposition has (i) a viscosity of less than 1200 cPs, about 100 toabout 1200 cPs, about 200 to about 1200 cps, or about 300 to about 600cPs and a solids content of at least 40%, 45%, 50%, 55%, 60%, 65% or 70%dry solids (ds) basis, or (ii) a viscosity of about 300 to about 600 cPsand a solids content of at least 60% dry solids (ds) basis; and,optionally, wherein the viscosity is measured on a Brookfield Viscometerat 20 rpm at 18.3° C.

12. The paper coating composition of embodiment 10 or 11, wherein saidcomposition contains from 2 to 20 parts of the starch and from 5 to 35parts of the plasticizer, from 2 to 10 parts of the starch and from 5 to25 parts of the plasticizer, or 10 parts of the starch and 25 parts ofthe plasticizer.

13. The paper coating composition of any one of embodiments 10-12,wherein said composition further comprises (i) a pigment, a latex, or amixture thereof; or (ii) about 100 parts pigment and about 10 to about25 parts latex.

14. A method of manufacturing a dry-finished, coated paper or paperboardproduct comprising applying the paper coating composition of any one ofembodiments 10-13 to at least one side of a paper or paperboard; andobtaining a dry finished, coated paper or paperboard.

15. The method of embodiment 14, wherein no starch is applied to thepaper or paperboard prior to or after the application of the papercoating composition.

16. The method of embodiment 14 or 15, with the proviso that the methoddoes not comprise a wet stack calendering step prior to applying thepaper coating composition of any one of embodiments 10-13.

17. The method of any one of embodiments 14-16, wherein the coatingcomposition is applied to the paper or paperboard at a coater.

18. A dry-finished, coated paper or paperboard product produced from themethod of any one of embodiments 14-17.

19. The dry-finished, coated paper or paperboard product of embodiment18, wherein the dry-finished paper or paperboard is characterized by asurface strength equivalent to that of a wet-finished paper orpaperboard product as measured by an IGT pick and blister test.

20. The dry-finished, coated paper or paperboard product of embodiment19, wherein the dry-finished paper or paperboard is characterized by anIGT average increase of at least 50%, 55%, 60%, 61%, 62%, 63%, 64%, 65%,66%, 67%, 68%, 69%, or 70% as compared to a dry-finished paper orpaperboard product coated with a standard coating.

21. A paper substrate comprising, on at least one surface, the papercoating composition of any one of embodiments 10-13.

EXAMPLES

The following examples are provided by way of illustration only and notby way of limitation. Those of skill in the art will readily recognize avariety of non-critical parameters that could be changed or modified toyield essentially the same or similar results. The examples should in noway be construed as limiting the scope of the present technology, asdefined by the appended claims

Materials and Methods

Coating Starch. PEN-COTE® L800 coating starch was obtained fromIngredion. PEN-COTE® D LV coating binder was also obtained fromIngredion. PEN-COTE® L800 coating starch is a stable liquid waxy starch(Ingredion, Inc.). PEN-COTE® D LV coating binder is a thinned starchthat can be added to a coating in a dry form or, alternatively,rehydrated and then added to a coating (Ingredion, Inc). A viscosityreduced hydroxypropyl modified waxy corn starch that has been fullycooked through a jet cooker (hereinafter “Liquid Starch Composition A”)(Ingredion, Inc.). A viscosity reduced ethylated dent corn starch thathas been fully cooked through a jet cooker (hereinafter “Liquid StarchComposition B”) (Ingredion, Inc.). A viscosity reduced OSA modified waxycorn starch that has been fully cooked through a jet cooker (hereinafter“Liquid Starch Composition C”) (Ingredion).

Plasticizers. Plasticizers used in the Examples include carbohydratederived plasticizers such as: ENZOSE® Brewers' Corn Syrup 55 DE orGLOBE® 55 HM Corn Syrup having a DE of 53 (“53 DE High Maltose CornSyrup”) (Ingredion, Inc.); GLOBE® 63 DE Corn Syrup having a DE of 60-67(Ingredion, Inc.); GLOBE® Plus 18 DE maltodextrin having a DE of 17-20(Ingredion, Inc.); VERSASWEET™ 1526 28 DE Glucose Syrup having a DE of26-30 (Ingredion, Inc.); INVERTOSE® HFCS 55 (Ingredion, Inc.) andINVERTOSE® HFCS 42 (Ingredion, Inc.), which are high fructose cornsyrups; Sucrose (Evaporated Cane Juice from Trader Joe's); and sorbitol(Ingredion, Inc.). Plasticizers used in the Examples also includenon-carbohydrate derived plasticizer such as: glycerin (FisherScientific), sorbitol (Ingredion, Inc.), and urea (Alpha Aesar).

Other Components. A clay pigment and vinyl acrylic latex were also addedto the coating compositions, either alone or in combination.

Paperboard Milling.

Procedure 1: The paperboard was produced on a multi-ply machine, with apress section and steam heated dryer cans. The dried paperboard was thencalendered and coated with a rod coater to which a paper coatingcomposition described herein was added. The paperboard was then coatedwith an airknife coater, dried, calendered again and wound up on a reel.

Procedure 2: The paperboard was produced on a multi-ply machine, with apress section and steam heated dryer cans. The dried paperboard was thencalendered and coated with a rod coater to which a paper coatingcomposition described herein was added.

IGT Pick and Blister Test. The Tappi Classical Test Method T 514 cm-92was used to assess surface strength.

Example 1 Preparing Paper Coating Compositions

Four paper coating compositions were prepared with the ingredients asshown in Table 1. Coating 1, the control coating, is a standard papercoating composition routinely used as a coated recycled paperboardbasecoat application. The control paper coating composition comprises100 parts Clay, 16 parts latex, and 5 parts PEN-COTE® L800 coatingstarch, with a viscosity of 680 cPs at 18.3° C. Coating 2 comprises 100parts Clay, 16 parts latex, 5 parts PEN-COTE® L800 coating starch, and30 parts 53 DE High Maltose Corn Syrup, with a viscosity of 160 cPs at18.3° C. Coating 3 comprises 100 parts Clay, 16 parts latex, 35 partsPEN-COTE® D LV coating binder (a thinned coating starch), with aviscosity of 1480 cPs at 18.3° C. Coating 4, the “high starch coating,”comprises 100 parts Clay, 16 parts latex, 10 parts PEN-COTE® L800starch, and 25 parts 53 DE High Maltose Corn Syrup, with a viscosity of560 cPs at 18.3° C. All coating parts were added based on dry solidsweight (parts is the standard convention for paperboard coatings wherethe pigment portion makes up 100 parts and all the other materials areadditive). Viscosity was measured using the Brookfield viscosity test.The test allows for a variety of RPMs to be employed. Viscositymeasurements were performed at 20 RPMs.

TABLE 1 Paper Coating Compositions Coating Solids Temp Viscosity CoatingComponents (%) (° C.) (cPs) 1 5 parts PEN-COTE ® 62.0 18.3 680 ControlL800 coating starch 100 parts Clay 16 parts Latex 2 5 parts PEN-COTE ®60.7 18.3 160 L800 coating starch 100 parts Clay 16 parts Latex 30 parts53 DE High-Maltose Corn Syrup 3 35 parts PEN-COTE ® 62.0 18.3 1480 D LVcoating binder 100 parts Clay 16 parts Latex 4 10 parts PEN-COTE ® 63.218.3 560 High L800 coating starch Starch 100 parts Clay Coating 16 partsLatex 25 parts 53 DE High- Maltose Corn Syrup

The data presented in Table 1 shows that the addition of 30 parts of 53DE High-Maltose Corn Syrup decreases the viscosity of the standard(“Control”) starch coating by more than 75% (coating 2). Increasing thestarch content of coating 3 to achieve a similar coating solids contentas for coatings 1, 2, and 4, results in the composition becoming tooviscous. The data also shows that, with the addition of 25 parts of 53DE High-Maltose Corn Syrup, the amount of PEN-COTE® L800 coating starchin the composition can be doubled from 5 parts to 10 parts (coating 4),while still producing a coating with an acceptable viscosity.

Example 2 The High Starch Paper Coating Composition of the PresentTechnology Enables Production of a Dry Finish Board with StrengthCharacteristics Similar to Those of a Wet Finish Board

A trial was run on a pilot coater in accordance with the Paper BoardMilling, Procedure 1 set forth hereinabove. Wet finished uncoated boardand dry finished uncoated board were used as the substrates. A wetfinished uncoated board was rod coated with Coating 1 set forth inTable 1. The wet finish board was produced by adding starch to the wetstack calender prior to the coaters. A first dry finished board was rodcoated with Coating 1 set forth in Table 1. A second dry finished boardwas rod coated with the high starch containing coating of Coating 4 setforth in Table 1. The dry finish board was produced without addingstarch to the wet stack calender prior to the coaters. All 3 boards weresubsequently top coated with a control airknife topcoat. The boards werecalendered after coatings applied and then tested. Coatings 1 and 4 fromTable 1 were applied on a 2.5 lbs/msf (12.21 grams/m²) base sheet foreach test group.

As shown in Table 2, the high starch coating (coating 4) had an IGTaverage increase of 63%, as compared to the standard coating (coating 1)on the dry finished board. In addition, the dry finished boards coatedwith the high starch coating (coating 4) exhibited on average a slightlyhigher blister IGT than the standard coating (coating 1) on a wetfinished paperboard.

TABLE 2 IGT Results For Wet Finish And Dry Finish Boards Using StandardAnd High Starch Coatings Wet Finish- Dry Finish- Dry Finish-HighStandard Coating Standard Coating Starch Coating (Coating 1, Table 1)(Coating 1, Table 1) (Coating 4, Table 1) IGT IGT IGT Pick Blister PickBlister Pick Blister (KPCMS) (KPCMS) (KPCMS) (KPCMS) (KPCMS) (KPCMS) 7156 39 38 74 78 73 76 43 46 68 70 76 66 46 45 66 76 Avg = 73.3 Avg = 66Avg = 43 Avg = 43 Avg = 69 Avg = 75

These results demonstrate that the paper coating compositions describedherein provide an improved method for manufacturing paperboard. Asdemonstrated herein, the use of a high starch coating compositionsdescribed herein in a dry finished board coating process confersstrength and quality characteristics comparable to those resulting fromthe use of a standard starch coating composition in a wet finished boardcoating process. Surprisingly, the addition of maltose corn syrup to apaper coating composition (coating 4) reduced the viscosity of thecoating and allowed more starch to be added to the paper coatingcomposition, thereby enabling the production of a paper coatingcomposition with a higher starch solids content. The higher starchsolids content of the paper coating composition enabled the wet stackcalender to be eliminated from the paper coating process, therebydecreasing manufacturing time and costs associated therewith. Asillustrated in Table 1, the starch content can be doubled (from 5 partsto 10 parts) while producing a coating that has a lower viscosity than astandard coating (coating 1).

Accordingly, these results demonstrate that the paper coatingcompositions described herein permit for elimination of a wet stackcalender step in the paper manufacturing process. Ordinarily, if the wetstack calender step is removed from the process, the amount of starchapplied to the paperboard at the rod coater must be increased. However,for practical purposes, the additional starch that must be added at thecoater when the wet stack calender is removed cannot increase theviscosity of the coating. As shown herein, the compositions of thepresent technology enable additional starch to be added to the papercoating compositions applied via the rod coaters without increasing theviscosity, thereby permitting the elimination of the wet stackcalendering step without compromising the strength and quality of thefinished paperboard product.

Example 3 Preparing Paper Coating Compositions Containing a Variety ofStarch Derived Syrups and Testing Strength Characteristics

Additional paper coating compositions were prepared with the ingredientsas shown in Table 3. The coating 5 control composition is a standardpaper coating composition routinely used as a basecoat to coat recycledpaperboard. The coating 5-22 compositions are coatings compositionsprepared in accordance with the present invention with a variety ofstarch derived syrups. All coating parts were added based on dry solidsweight (parts is the standard convention for paperboard coatings wherethe pigment portion makes up 100 parts and all the other materials areadditive) using an overhead mixer. Viscosity was measured using theBrookfield viscosity test. The test allows for a variety of RPMs to beemployed. Viscosity measurements were performed at a temperature of23.9° C. using spindle 4 at 20 RPMs. The solids content of the coating5-16 and 19-22 compositions was measured using a moisture balance(available from Mettler-Toledo Ltd., Beaumont Ley, Leicester, UK). Thesolids content of the coating 17-18 compositions was calculated based onthe solids content of the ingredients used as measured or provided bythe manufacturer.

Each coating 5-22 composition was coated on a dry finished board inaccordance with the Paper Board Milling, Procedure 2 set forthhereinabove using a hand drawdown process using a rod. None of theboards were subsequently top coated.

Each of the Table 3 coating 6-22 compositions exhibited a lowerviscosity in combination with improved strength characteristics than thecoating 5 control composition.

TABLE 3 Additional Paper Coating Compositions & Associated StrengthCharacteristics IGT Coating Pick Avg Blister Avg Solids Temp Viscosity(n = 2) (n = 2) Coating Components (%) (° C.) (cPs) (KPCMS) (KPCMS)  5 5parts PEN-COTE ® L800 coating starch 62.1 23.9 1420 22 19 Control 100parts Clay 16 parts Latex  6 5 parts PEN-COTE ® L800 coating starch 61.623.9 1040 28 24 100 parts Clay 16 parts Latex 10 parts GLOBE ® Plus 18DE Maltodextrin  7 3 parts PEN-COTE ® L800 coating starch 62.0 23.9 65024 19 100 parts Clay 16 parts Latex 12 parts GLOBE ® Plus 18 DEMaltodextrin  8 5 parts PEN-COTE ® L800 coating starch 61.7 23.9 1000 3522 100 parts Clay 16 parts Latex 10 parts VERSASWEET ™ 1526 28 DEGlucose Syrup  9 5 parts PEN-COTE ® L800 coating starch 61.5 23.9 620 2420 100 parts Clay 16 parts Latex 10 parts ENZOSE ® Brewers’ Corn Syrup55DE 10 3 parts PEN-COTE ® L800 coating starch 62.0 23.9 550 30 24 100parts Clay 16 parts Latex 12 parts ENZOSE ® Brewers’ Corn Syrup 55DE 115 parts PEN-COTE ® L800 coating starch 61.7 23.9 720 31 22 100 partsClay 16 parts Latex 10 parts INVERTOSE ® HFCS 55 12 3 parts PEN-COTE ®L800 coating starch 61.7 23.9 390 29 22 100 parts Clay 16 parts Latex 12parts INVERTOSE ® HFCS 55 13 5 parts PEN-COTE ® L800 coating starch 61.823.9 660 27 21 100 parts Clay 16 parts Latex 10 parts INVERTOSE ® HFCS42 14 3 parts PEN-COTE ® L800 coating starch 61.9 23.9 520 27 26 100parts Clay 16 parts Latex 12 parts INVERTOSE ® HFCS 42 15 5 partsPEN-COTE ® L800 coating starch 61.6 23.9 840 27 23 100 parts Clay 16parts Latex 10 parts GLOBE ® 63 DE Corn Syrup 16 3 parts PEN-COTE ® L800coating starch 61.9 23.9 700 31 27 100 parts Clay 16 parts Latex 12parts GLOBE ® 63 DE Corn Syrup 17 5 parts PEN-COTE ® L800 coating starch62 23.9 600 27 34 100 parts Clay 16 parts Latex 10 parts Glycerin 18 3parts PEN-COTE ® L800 coating starch 62 23.9 450 27 23 100 parts Clay 16parts Latex 12 parts Glycerin 19 5 parts PEN-COTE ® L800 coating starch62.0 23.9 670 27 21 100 parts Clay 16 parts Latex 10 parts sucrose 20 3parts PEN-COTE ® L800 coating starch 62.0 23.9 490 26 19 100 parts Clay16 parts Latex 12 parts sucrose 21 5 parts PEN-COTE ® L800 coatingstarch 61.6 23.9 720 32 28 100 parts Clay 16 parts Latex 10 partssorbitol 22 3 parts PEN-COTE ® L800 coating starch 61.9 23.9 520 28 28100 parts Clay 16 parts Latex 12 parts sorbitol

Example 4 Preparing Paper Coating Compositions Containing a Variety ofStarches and Testing Strength Characteristics

Additional paper coating compositions were prepared with the ingredientsas shown in Table 4. The coating 23 control composition is a standardpaper coating composition routinely used as a basecoat to coat recycledpaperboard. The coating 24-31 compositions are coating compositionsprepared in accordance with the present invention with a variety ofstarches. All coating parts were added based on dry solids weight (partsis the standard convention for paperboard coatings where the pigmentportion makes up 100 parts and all the other materials are additive)using an overhead mixer. Viscosity was measured using the Brookfieldviscosity test. The test allows for a variety of RPMs to be employed.Viscosity measurements were performed at a temperature of 23.9° C. usingspindle 4 at 20 RPMs. The solids content of the coating 23-31compositions was measured using a moisture balance (available fromMettler-Toledo Ltd., Beaumont Ley, Leicester, UK).

Each coating 23-31 composition was coated on a dry finished board inaccordance with the Paper Board Milling, Procedure 2 set forthhereinabove using a hand drawdown process using a rod. None of theboards were subsequently top coated.

Each of the Table 4 coating compositions 24-31 exhibited a lowerviscosity in combination with improved strength characteristics than thecoating 23 control composition.

TABLE 4 Additional Paper Coating Compositions & Associated StrengthCharacteristics IGT Coating Pick Avg Blister Avg Solids Temp Viscosity(n = 2) (n = 2) Coating Components (%) (° C.) (cPs) (KPCMS) (KPCMS) 23 5parts PEN-COTE ® L800 coating starch 62.1 23.9 1420 22 19 Control 100parts Clay 16 parts Latex 24 5 parts Liquid Starch Composition A 61.323.9  880 29 26 100 parts Clay 16 parts Latex 10 parts urea 25 3 partsLiquid Starch Composition A 61.4 23.9  520 26 22 100 parts Clay 16 partsLatex 12 parts urea 26 5 parts Liquid Starch Composition A 62.1 23.91180 28 25 100 parts Clay 16 parts Latex 10 parts ENZOSE ® Brewers’ CornSyrup 55DE 27 3 parts Liquid Starch Composition A 62.0 23.9  830 30 29100 parts Clay 16 parts Latex 12 parts ENZOSE ® Brewers’ Corn Syrup 55DE28 5 parts Liquid Starch Composition B 62.0 23.9 1080 30 30 100 partsClay 16 parts Latex 10 parts ENZOSE ® Brewers’ Corn Syrup 55DE 29 3parts Liquid Starch Composition B 62.2 23.9  640 31 28 100 parts Clay 16parts Latex 12 parts ENZOSE ® Brewers’ Corn Syrup 55DE 30 5 parts LiquidStarch Composition C 62.8 23.9 1350 31 26 100 parts Clay 16 parts Latex10 parts ENZOSE ® Brewers’ Corn Syrup 55DE 31 3 parts Liquid StarchComposition C 62.2 23.9  750 33 26 100 parts Clay 16 parts Latex 12parts ENZOSE ® Brewers’ Corn Syrup 55DE

Example 5 Paper Coating Composition has Improved Surface StrengthCharacteristics without Sacrificing Other Physical Characteristics

Paper coating compositions were prepared with the ingredients as shownin Table 5. The coating 32 control composition is a standard papercoating composition routinely used as a basecoat to coat recycledpaperboard. The coating 33 composition was prepared in accordance withthe present invention. All coating parts were added based on dry solidsweight (parts is the standard convention for paperboard coatings wherethe clay portion makes up 100 parts and all the other materials areadditive) using an overhead mixer.

Each coating 32-33 composition was coated on a dry finished board inaccordance with the Paper Board Milling, Procedure 2 set forthhereinabove using a hand drawdown process using a rod. None of theboards were subsequently top coated. For Tables 5 and 6, the surface andphysical characteristics of the coated paper boards were measured atleast three times and reported as an average (“Avg”) measurement.

TABLE 5 Additional Paper Coating Compositions & Associated StrengthCharacteristics IGT Coating Pick Avg Blister Avg Solids Temp Viscosity(n ≥ 3) (n ≥ 3) Coating Components (%) (° C.) (cPs) (KPCMS) (KPCMS) 32100 parts Clay 54.0 25 125 38.2  24.2 Control 21 parts Latex 33 9 partsPEN-COTE ® coating starch 54.0 25 157 59.67 24   High 9 parts ENZOSE ®brewers corn syrup 55DE Starch 100 parts Clay 18 parts Latex

The data shown in Tables 5 and 6 show that adding the coating starch andplasticizer and decreasing the ratio of starch to pigment from 4.8:1 inCoating 32 (“Control”) to a ratio of 2.9:1 while leaving the coatingsolids percentage unchanged (Coating 33), resulted in a slight increasein the viscosity that was coupled to a surprising improvement in surfacestrength characteristics. The average IGT Pick value increased by morethan 56%, while the average IGT Blister value increased by more than97%. The data in Table 6 further shows that the high starch 33composition displayed a significant improvement in surface strengthcharacteristics without suffering a loss in the quality of the basisweight, caliper, base coat weight, coated brightness, Appearance DAV2,Appearance DMM, or Sheffield smoothness. The physical characteristicsrelated to the weight, thickness, and appearance of the coated papersurface remained unchanged or substantially unchanged, when comparingthe coating 32 control composition and high starch 33 compositionapplied to paper boards.

TABLE 6 Physical Characteristics of Additional Paper CoatingCompositions Basis Base Coat Coated Sheffield Weight Caliper WeightBrightness Appearance Appearance Smoothness IGT Avg Avg Avg Avg DAV2 DMMAvg Viscosity Pick Avg Blister Avg Coating (g/m²) (.0001 in) (g/m²)(points) Avg Avg (sec) (cPs) (KPCMS) (KPCMS) 32 65.8 18.1 1.4 79.8 58.127.9 153.2 125 38.2 24.2 Control 33 65.8 18.1 1.5 79.0 58.3 27.8 156.7157 59.7 37.6 High Starch

The present technology is not to be limited in terms of the particularembodiments described in this application, which are intended as singleillustrations of individual aspects of the present technology. Manymodifications and variations of this present technology can be madewithout departing from its spirit and scope, as will be apparent tothose skilled in the art. Functionally equivalent methods andapparatuses within the scope of the present technology, in addition tothose enumerated herein, will be apparent to those skilled in the artfrom the foregoing descriptions. Such modifications and variations areintended to fall within the scope of the appended claims. The presenttechnology is to be limited only by the terms of the appended claims,along with the full scope of equivalents to which such claims areentitled. It is to be understood that this present technology is notlimited to particular methods, reagents, compounds compositions orbiological systems, which can, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting.

In addition, where features or aspects of the disclosure are describedin terms of Markush groups, those skilled in the art will recognize thatthe disclosure is also thereby described in terms of any individualmember or subgroup of members of the Markush group.

As will be understood by one skilled in the art, for any and allpurposes, particularly in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a nonlimiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the like,include the number recited and refer to ranges which can be subsequentlybroken down into subranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember. Thus, for example, a group having 1-3 cells refers to groupshaving 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers togroups having 1, 2, 3, 4, or 5 cells, and so forth.

All patents, patent applications, provisional applications, andpublications referred to or cited herein are incorporated by referencein their entirety, including all figures and tables, to the extent theyare not inconsistent with the explicit teachings of this specification.Other embodiments are set forth within the following claims.

1. A coating starch composition comprising a starch and a plasticizer,wherein said composition has a starch and plasticizer solids level of atleast 40% dry solids basis.
 2. The coating starch composition of claim1, wherein said composition contains 1 part of a starch for each 1, 1.5,2, 2.5, 3, 3.5, or 4 parts of a plasticizer.
 3. The coating compositionof claim 1, where said plasticizer is a non-carbohydrate derivedplasticizer, a carbohydrate derived plasticizer, or a mixture thereof.4. The coating composition of claim 3, where said non-carbohydratederived plasticizer is selected from urea, glycerin/glycerol, formamide,citric acid or other carboxylic acids, ethylene glycol, and a mixture ofany two or more of the foregoing.
 5. The coating composition of claim 3,where said carbohydrate derived plasticizer is (i) a sugar; (ii) asucrose, a starch derived syrup, a maltodextrin, a dextrin, a sugaralcohol, or a mixture of any two or more of the foregoing; (iii) astarch derived syrup selected from a corn syrup, a low sugar syrup,dextrose, or a mixture of any two or more of the foregoing; (iv) amaltose corn syrup or a high fructose corn syrup; or (v) a sorbitol. 6.The coating composition of claim 5, wherein said starch derived syruphas a dextrose equivalency of about 20 to about 90, about 20 to about100, about 40 to about 75, about 40 to about 70, about 40 to about 44,about 49 to about 55, about 53 or
 53. 7. The coating starch compositionof claim 1, wherein said plasticizer is a corn syrup selected frommaltose corn syrup, high fructose corn syrup, and a mixture thereof. 8.The coating starch composition of claim 1, wherein the starch is amodified starch selected from a nonionic starch, an anionic starch, anamphoteric starch, an etherified starch, an acetylated starch, asulfonated starch, and a mixture of any two or more of the foregoing:optionally, wherein the starch is selected from corn starch, dent cornstarch, waxy corn starch, wheat starch, potato starch, tapioca starch,pea starch, sorghum starch, manioc starch, sago starch, rice starch, anda mixture of any two or more of the foregoing.
 9. (canceled)
 10. A papercoating composition comprising the coating starch composition of claim1, wherein said composition contains at least about 2%, from about 2% toabout 30%, from about 2% to about 25%, from about 2% to about 22%, orfrom about 2% to about 10% starch.
 11. The paper coating composition ofclaim 10, wherein the composition has (i) a viscosity of less than 1200cPs, about 100 to about 1200 cPs, about 200 to about 1200 cPs, or about300 to about 600 cPs and a solids content of at least 40%, 45%, 50%,55%, 60%, 65% or 70% dry solids basis, or (ii) a viscosity of about 300to about 600 cPs and a solids content of at least 60% dry solids basis;and, optionally, wherein the viscosity is measured on a BrookfieldViscometer at 20 rpm at 18.3° C.
 12. The paper coating composition ofclaim 10, wherein said composition contains from 2 to 20 parts of thestarch and from 5 to 35 parts of the plasticizer, from 2 to 10 parts ofthe starch and from 5 to 25 parts of the plasticizer, or 10 parts of thestarch and 25 parts of the plasticizer.
 13. The paper coatingcomposition of claim 10, wherein said composition further comprises (i)a pigment, a latex, or a mixture thereof; or (ii) about 100 partspigment and about 10 to about 25 parts latex.
 14. A method ofmanufacturing a dry-finished, coated paper or paperboard productcomprising applying the paper coating composition of claim 10 to atleast one side of a paper or paperboard; and obtaining a dry finished,coated paper or paperboard.
 15. The method of claim 14, wherein nostarch is applied to the paper or paperboard prior to or after theapplication of the paper coating composition.
 16. The method of claim14, with the proviso that the method does not comprise a wet stackcalendering step prior to applying the paper coating composition. 17.The method of claim 14, wherein the coating composition is applied tothe paper or paperboard at a coater.
 18. A dry-finished, coated paper orpaperboard product produced from the method of claim
 14. 19. Thedry-finished, coated paper or paperboard product of claim 18, whereinthe dry-finished paper or paperboard is characterized by a surfacestrength equivalent to that of a wet-finished paper or paperboardproduct as measured by an IGT pick and blister test.
 20. Thedry-finished, coated paper or paperboard product of claim 19, whereinthe dry-finished paper or paperboard is characterized by an IGT averageincrease of at least 50%, 55%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%,68%, 69%, or 70% as compared to a dry-finished paper or paperboardproduct coated with a standard coating.
 21. A paper substratecomprising, on at least one surface, the paper coating composition ofclaim 10.